Owens Corning Kansas City plant - Executive Summary

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Owens Corning is committed to achieving environmental leadership  
within its industry and beyond.  The Insulation Systems Business Unit  
(ISB), of which the Kansas City Insulation Plant is a key part,  
demonstrates this pursuit of excellence by proactively managing its  
operations to reduce environmental impacts while improving the quality  
of its products and the well-being of its employees and the community.   
ISB Environmental has implemented a programmatic approach to  
compliance with the EPA's Risk Management Program (RMP) Rule.  All of  
the business unit's manufacturing facilities will address process safety and  
risk management issues for key materials utilized by the plants in  
manufacturing fiberglass insulation products. The program will fulfill the  
general duty clause requirement in the RMP rule.  Facilities, like Kansas  
City, with threshold quantities above the RMP triggers, have utilized a  
management manual system to comply with the 
requirements of RMP.   
This submittal only characterizes the subject processes that require a RMP  
submittal and certification by June 21, 1999. 
The Kansas City plant holds Environmental Stewardship, along with  
Safety, Productivity, and Quality, as one of its (4) driving principles.   
Located in the Fairfax Industrial District for 52 years, the Kansas City  
plant is an integral part of the Kansas City, Kansas community.   
Membership in such organizations as Friends of Fairfax and the  
Wyandotte County Coalition for Chemical Safety emphasize the  
importance with which the plant views their commitment. 
Owens Corning is committed to developing and operating its  
manufacturing facilities in a manner protective of the environment and  
human health.  This priority is expressed through continuing process  
improvement, risk reduction, and an emphasis on pollution prevention. 
In order to produce the quality products that Ow 
ens Corning is known  
for, the Kansas City facility uses a 50% formaldehyde solution in the  
manufacturing of fiberglass binder resin for use at the facility.  Because  
this is a toxic chemical, numerous controls have been implemented to  
prevent an accidental release of this chemical.  In the event of a release, the  
Kansas City facility has an emergency response program that will be  
implemented.  This program is made up of hourly and management  
employees who have been properly trained in certain elements of  
emergency response, as well as communication with the appropriate  
responder organizations in the community. 
The Kansas City facility, located at 300 Sunshine Road in Kansas City,  
Kansas, is a producer of wool glass fibers, which are fabricated into  
insulation materials.  Glass fiber manufacturing involves the high- 
temperature conversion of various materials into a homogeneous melt,  
followed by the fabrication of thi 
s melt into glass fibers.  After the  
formation of the glass fibers, a thermosetting chemical binder solution is  
applied to the fibers.  The glass fibers and binder solution are then  
collected on a conveyor belt where they are sent through a large curing  
oven and then through a cooling section.  The result is a mat that is then  
cut into batts or rolls of the desired dimensions and then packaged. 
Kansas City Insulation plant has a single covered process that is subject to  
RMP.  The 50% formaldehyde solution that is utilized in a process to  
manufacture the binder resin is a Program Level 3 process.  The  
formaldehyde resin is a binder system ingredient used to manufacture  
wool fiberglass insulation at the plant.  
Owens Corning has determined the distance to the toxic endpoints for the  
regulated substance present at the Kansas City facility.  The following  
release scenarios have been considered: 
50% Formaldehyde     
Aqueous formaldehyde is stored in 
two 15,000-gallon  
storage tanks.  The tanks are located in a diked  
containment area.  Trucks unload the material  
through a 3-inch hose.  All truck unloading takes  
place in a separate containment area designed for that  
purpose.  Both the storage tanks and the truck are  
maintained at 150? F.   
Worst-case release is an instantaneous release of the  
maximum inventory of one tank, which forms a  
liquid pool in the dike.  The release duration is  
assumed to be 60-minutes because the concentration  
of formaldehyde in solution after 10-minutes of  
evaporation is not significantly lower than the initial  
Distance to Endpoint  -    0.456 miles  (ALOHA) 
The alternative release involves a failure of the  
unloading hose during product delivery resulting in a  
release of 500 gallons over a 5-minute period.  The  
liquid released from the line/hose break is contained  
in the truck unloading area. 
Distance to Endpoint  -    0.116 miles  (ALOHA) 
The release scenarios examine 
d above could result in off-site impact.  Both  
OCA guidance look-up table values and air dispersion modeling results  
for the toxic compounds via ALOHA were examined and reported as  
Mitigation measures were considered in formulating the alternative  
scenarios since unloading incidents are the most commonly occurring  
accident type.  
Accidental releases are mitigated by an aggressive spill reporting program  
and operator and Emergency Response Team training in spill response. 
No documented off-site impacting accidents have occurred within the last  
five years. 
Kansas City maintains an up-to-date Emergency Response Plan and  
conducts annual drills to train on response procedures.  In addition, the  
Kansas City plant maintains an Emergency Response Team on all shifts.   
The Emergency Response Team is trained in personal rescue, fir 
st aid, and  
response to chemical release. 
The following list of capital improvements represents an investment of  
approximately $100,000 made during the last two years in upgraded  
process safety controls and other equipment to mitigate and reduce the  
prospect of an accidental release. 
   Formaldehyde Storage Tanks - Barrier Wall 
   Redesign of Formaldehyde Scrubber 
   Pipe Bridge spill containment - Tank Farm to Binder Room 
   Pipe Bridge spill containment - Phenol unloading to Reactor Building 
   Pipe Bridge spill containment - Tank Farm to Reactor Building 
   Ultrasonic probe level monitors installed - Formaldehyde and Phenol  
   Freeze protection enclosures around critical unloading and transfer  
   Grounding of tanks 
   Replaced much hot water heat tracing with electric 
   New surface on reactor containment area 
   Modified resin recirculation loop, and added double-sealed pump 
In 1998, the plant received approval for a three-year extensive pr 
for upgrade of facilities associated with the chemical processes  
surrounding resin manufacture and binder mixing (of which some of the  
above-mentioned projects are a part).  This program, aimed primarily at  
release prevention and automation of certain manual processes, will  
further reduce likelihood of accidental chemical releases.  The total value  
of this capital investment is $924,000 
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